Mitsubishi Evolution VI 1999-2001 Factory Service Manual
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๐ท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Model Nickname: Evo VI Codes Chassis Code Prefix: CP9A Engine Code Prefix: 4G63 ๐ Introduction Market Position Segment: Rally homologation special, performance sedan Reputation: Legendary status in motorsport and enthusiast communities Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione Key Features Performance Focus: Aggressive styling, turbocharged engine, advanced all-wheel-drive system Rally Heritage: Developed from the Lancer platform for World Rally Championship (WRC) success ๐ Manual Details Coverage Areas Applicable Years: 1999, 2000, 2001 Regions Covered: Global (primarily Japan domestic market focus) Page Count Estimated Pages: Hundreds (specific count not provided, but described as 'complete') Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English (implied by 'PDF Download' and common industry practice for exported manuals) Format Format: PDF Download ๐ Manual Coverage Systems Covered Powertrain: Engine mechanical, engine performance, fuel system, cooling system, lubrication system, ignition system, exhaust system, transmission (manual and automatic variants), drivetrain (front/rear differentials, transfer case, axles) Chassis: Suspension (front MacPherson strut, rear multi-link), steering, brakes (ABS, hydraulic components), wheels and tires, chassis electrical Body And Interior: Body construction, exterior panels, doors, windows, interior trim, seating, HVAC system, airbags Electrical And Electronics: Wiring diagrams, electrical troubleshooting, lighting system, audio system, ECU, sensors, actuators Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, lubrication points Troubleshooting: Diagnostic procedures, symptom-based troubleshooting, fault code interpretation Repair And Rebuild: Component removal and installation, overhaul procedures, torque specifications, assembly instructions Special Procedures: Alignment, wheel balancing, specialized tool usage Technical Depth Depth: Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts ๐ Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if OCR processed, enhancing usability Print Quality Printable: Yes, designed for printing by the user Resolution: High quality, suitable for clear reproduction of diagrams and text Binding Type User Binding Options: Printable allows for user binding (e.g., three-hole punch, spiral binding) Paper Type Recommended Paper: Standard printer paper, with higher weight recommended for durability โ๏ธ Engine Specifications Primary Engine Engine Family: Mitsubishi Sirius / 4G6 (2.0L DOHC Turbo) Engine Displacement: 1997 cc (2.0 Liters) Engine Configuration: Inline-4, turbocharged and intercooled Performance Horsepower Ps: 280 PS (276 hp; 206 kW) at 6500 rpm (JDM specification, often higher in reality) Torque Nm: 373 Nm (275 lb-ft) at 3000 rpm (JDM specification) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-point injectors Fuel Type: Unleaded Premium Gasoline (95 RON or higher recommended) Engine Internals Block Material: Cast Iron (known for strength) Head Material: Aluminum Alloy Turbocharger Turbo Model: Mitsubishi TD05HR-16G (twin-scroll) Engine Management ECU Type: Electronic Control Unit (ECU) with engine management system ๐ง Transmission Standard Type: 5-speed Manual Transmission (Getrag-based, often referred to as RS gearbox) Optional Type: 4-speed Automatic Transmission (available on some markets, less common for performance variants) Features Awc System: Active Centre Differential (ACD) and Active Yaw Control (AYC) or Super AYC on some models, integrated with transmission and drivetrain Fluid Specifications Manual Transmission Fluid Type: API GL-4 or GL-5, viscosity typically 75W-90 Automatic Transmission Fluid Type: Dexron III or equivalent (if applicable) ๐ Dimensions Exterior Length: 4340 mm (170.9 in) Width: 1770 mm (69.7 in) Height: 1405 mm (55.3 in) Wheelbase: 2600 mm (102.4 in) Track Front: 1510 mm (59.4 in) Track Rear: 1505 mm (59.3 in) Weights Curb Weight: Approx. 1360 kg (2998 lbs) for GSR model Gross Vehicle Weight Rating: Not specified, but typically around 1800-1900 kg Wheels And Tires Standard Wheel Size: 17 x 7.5 inches Standard Tire Size: 215/40R17 Bolt Pattern: 5x114.3 mm (5x4.5 inches) ๐ก๏ธ Safety Features Ratings Crash Test Results: No official NHTSA/Euro NCAP ratings for this specific model year due to its homologation-based nature and target market. However, built to meet rigorous WRC safety standards. Active Features Braking System: Front: Ventilated discs, Rear: Ventilated discs. Brembo calipers standard on GSR. ABS standard. Traction Control: Advanced electronically controlled All-Wheel Control (AWC) system including ACD and AYC/Super AYC. Passive Features Airbags: Driver and front passenger airbags standard. Body Structure: Reinforced chassis and safety cage for rally-derived strength. ๐ก Technology Features Infotainment Audio System: Factory radio with CD player and speakers. Aftermarket upgrades are common. Driver Assistance Advanced AWD: The defining technology: ACD (Active Centre Differential) and AYC/Super AYC (Active Yaw Control) for superior traction and handling. Connectivity Original Connectivity: Basic for its era, focused on vehicle performance rather than extensive connectivity features. ๐ง Maintenance Service Intervals Oil Change Interval: Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first, especially under hard driving conditions. Air Filter Replacement: Every 20,000-30,000 km (12,000-18,000 miles) or as needed based on driving environment. Spark Plug Replacement: Platinum or Iridium plugs typically last 80,000-100,000 km (50,000-60,000 miles). Fluid Specifications Engine Oil Type:...
Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts
๐ Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if OCR processed, enhancing usability
Print Quality
Printable:
Yes, designed for printing by the user
Resolution:
High quality, suitable for clear reproduction of diagrams and text
Binding Type
User Binding Options:
Printable allows for user binding (e.g., three-hole punch, spiral binding)
Paper Type
Recommended Paper:
Standard printer paper, with higher weight recommended for durability
โ๏ธ Engine Specifications
Primary Engine
Engine Family:
Mitsubishi Sirius / 4G6 (2.0L DOHC Turbo)
Engine Displacement:
1997 cc (2.0 Liters)
Engine Configuration:
Inline-4, turbocharged and intercooled
Performance
Horsepower Ps:
280 PS (276 hp; 206 kW) at 6500 rpm (JDM specification, often higher in reality)
Torque Nm:
373 Nm (275 lb-ft) at 3000 rpm (JDM specification)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with multi-point injectors
Fuel Type:
Unleaded Premium Gasoline (95 RON or higher recommended)
Engine Internals
Block Material:
Cast Iron (known for strength)
Head Material:
Aluminum Alloy
Turbocharger
Turbo Model:
Mitsubishi TD05HR-16G (twin-scroll)
Engine Management
ECU Type:
Electronic Control Unit (ECU) with engine management system
๐ง Transmission
Standard
Type:
5-speed Manual Transmission (Getrag-based, often referred to as RS gearbox)
Optional
Type:
4-speed Automatic Transmission (available on some markets, less common for performance variants)
Features
Awc System:
Active Centre Differential (ACD) and Active Yaw Control (AYC) or Super AYC on some models, integrated with transmission and drivetrain
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 or GL-5, viscosity typically 75W-90
Automatic Transmission Fluid Type:
Dexron III or equivalent (if applicable)
๐ Dimensions
Exterior
Length:
4340 mm (170.9 in)
Width:
1770 mm (69.7 in)
Height:
1405 mm (55.3 in)
Wheelbase:
2600 mm (102.4 in)
Track Front:
1510 mm (59.4 in)
Track Rear:
1505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1360 kg (2998 lbs) for GSR model
Gross Vehicle Weight Rating:
Not specified, but typically around 1800-1900 kg
Wheels And Tires
Standard Wheel Size:
17 x 7.5 inches
Standard Tire Size:
215/40R17
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
๐ก๏ธ Safety Features
Ratings
Crash Test Results:
No official NHTSA/Euro NCAP ratings for this specific model year due to its homologation-based nature and target market. However, built to meet rigorous WRC safety standards.
Active Features
Braking System:
Front: Ventilated discs, Rear: Ventilated discs. Brembo calipers standard on GSR. ABS standard.
Traction Control:
Advanced electronically controlled All-Wheel Control (AWC) system including ACD and AYC/Super AYC.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Body Structure:
Reinforced chassis and safety cage for rally-derived strength.
๐ก Technology Features
Infotainment
Audio System:
Factory radio with CD player and speakers. Aftermarket upgrades are common.
Driver Assistance
Advanced AWD:
The defining technology: ACD (Active Centre Differential) and AYC/Super AYC (Active Yaw Control) for superior traction and handling.
Connectivity
Original Connectivity:
Basic for its era, focused on vehicle performance rather than extensive connectivity features.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first, especially under hard driving conditions.
Air Filter Replacement:
Every 20,000-30,000 km (12,000-18,000 miles) or as needed based on driving environment.
Spark Plug Replacement:
Platinum or Iridium plugs typically last 80,000-100,000 km (50,000-60,000 miles).
Fluid Specifications
Engine Oil Type:
Synthetic 5W-40 or 5W-50 recommended, meeting API SJ/SL or ACEA A3/B3/B4 standards.
Engine Oil Capacity:
Approximately 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Ethylene glycol based coolant, typically 50/50 mix with distilled water. (e.g., Mitsubishi Super Long Life Coolant or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4 (check specific manual for exact spec)
Known Issues
Engine Wear:
Piston ring land failures and connecting rod bending can occur with aggressive tuning or detonation. Regular maintenance and correct fueling are critical.
Ayc Pump:
AYC pump failure or leaks can occur over time, affecting rear-wheel steering performance.
Clutch:
Performance clutches may have shorter lifespans than standard clutches, especially under heavy use.
Maintenance Documentation Value
Importance For Evos:
Crucial for maintaining the complex AWD system, engine performance, and longevity of these highly tuned vehicles.
๐ Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a strong history in rallying, with the Lancer Evolution series being a dominant force.
Model Evolution
Evolution Series:
The Evolution VI (Evo VI) succeeded the Evo V and introduced styling and mechanical revisions, including a more aggressive front bumper and the introduction of the TME (Tommi Mรคkinen Edition) variant.
Sub Variants:
RS (Ralliart Sport - lightweight, homologation special) and GSR (Grand Sport Rally - more luxury-oriented, but still performance-focused). TME (Tommi Mรคkinen Edition) celebrated WRC driver's championships.
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
๐ Awards & Recognition
Recognitions
Motorsport Dominance:
Multiple WRC Manufacturer's and Driver's Championships for Mitsubishi and Tommi Mรคkinen.
Ratings
Enthusiast Appreciation:
Universally acclaimed as one of the greatest rally cars for the road ever produced.